Level Monitoring for Real-Time Molten Metal Level Measurement

With accurate real-time molten level tracking, the system saved over 10,000+ man-hours annually and increased production efficiency by 1–2%, enabling safer operations and more consistent performance.

Trusted by leading global enterprises

Problem Statement

Inaccurate molten metal level measurements led to overflows, bursts, or splashes, causing safety hazards, damage to furnace walls and tap holes, and unplanned production stoppages.

One of the top steel manufacturer struggled with inconsistent and inaccurate molten metal level measurements across its furnaces. Manual inspections exposed operators to safety risks and often failed to catch sudden level fluctuations, leading to operational inefficiencies and unplanned downtime.

Inaccurate metal levels measurement

Harsh furnace conditions like extreme heat, glare, smoke, and splashes obstructed visibility, while manual checking based on visual judgment often led to errors. This resulted in inaccurate molten metal level measurement, causing unplanned stoppages.

High risk of overflows, bursts, or splashes

High molten metal levels created a severe risk of overflows, bursts, and splashes, exposing operators to safety hazards and causing potential damage to furnace walls, tap holes, and equipment. These incidents disrupted production and increased maintenance needs.

Manual inspection of metal levels

Manual inspection of molten metal levels relied on visual judgment and dip rods, exposing operators to hazardous conditions and inaccurate readings. This manual process increased safety risks and often caused operational inefficiencies

Equipment
damage

Repeated thermal shock and metal contact weakened structural components, as frequent overflows and splashes damaged furnace walls, tap holes, and surrounding equipment—resulting in higher repair costs and unplanned downtime.

Solution

Ripik AI deployed a Vision AI–powered Level Monitoring System to deliver real-time, accurate molten metal level measurement for steel plants.

Specialized Hardware

The Level Monitoring System used specialized industrial-grade hardware, including high-temperature IR and optical cameras engineered to withstand extreme furnace environments. These rugged devices maintained accuracy despite heat, glare, and dust, ensuring reliable, real-time molten metal level measurements essential for stable and safe operations.

Live feed of molten steel levels

The molten level control system enabled real-time monitoring of molten steel levels, providing a live feed with zoomed views for detailed observation and real-time updates of operating parameters, ensuring precise tracking and faster decision-making.

Real-time alerts for level exceedance

The molten level monitoring system generated real-time alerts whenever molten metal levels exceeded safe limits, enabling operators to act immediately by reducing inflow during high-level detection, restricting access to unsafe areas, and making quick adjustments to maintain optimal furnace conditions.

Programmable Closed-Loop Water-Sprinkler Control to Regulate Inflow

The system offered programmable closed-loop control to automatically regulate molten metal inflow based on real-time level readings, along with automated water-sprinkler control for instant response to unsafe conditions. Together, these capabilities maintained stable levels, prevented overflows, and ensured safer, more consistent furnace operation.

Historical video feeds & insightful report

The system provided historical video feeds and insightful reports with in-depth analysis of molten metal levels and alert trends, helping teams identify recurring patterns, assess operational stability, and make data-driven improvements to furnace performance.

Impact and Validation by End Users

Delivered accurate molten metal level measurement in steel plants

The computer vision–based level monitoring platform enabled operators to take timely action by reducing molten metal inflow when high levels were detected, restricting access to unsafe areas for enhanced worker safety, and making prompt operational adjustments to maintain optimal furnace conditions and prevent disruptions.

1.5M$

Annually saved

The molten level measurement system reduced equipment damage, optimized molten metal inflow, and minimized unplanned shutdowns, collectively contributing to substantial annual financial savings of $1.5 million.

10,000+

Man-hours saved annually

By eliminating manual level checks and reducing operator exposure to hazardous furnace zones, the plant saved over 10,000 man-hours annually, improving safety and operational efficiency.

1-2%

Increase in production efficiency

Accurate real-time molten metal level tracking ensured more stable furnace operations, reduced process delays, and improved consistency—resulting in a 1–2% increase in overall production efficiency.

OUR success stories

Our role in driving
customer success

See how leading companies across steel, cement, oil & gas, energy, automotive, chemicals, pharmaceuticals, FMCG, and other industries are transforming their operations with Ripik AI’s Vision AI solutions—driving real-time insights, enhanced safety, and intelligent process optimizations across the industrial landscape